Variable Reluctance Resolver Terminal Pin Protection
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Solution Overview
Problem
Variable Reluctance resolvers face issues with terminal pin deformation, shorting, and contact failure due to external loads and environmental factors like water, dust, and dirt entering between exposed terminal pins.
Innovation Solution
A VR resolver design that includes a cover to protect terminal pins with a non-conductive material filling the hollow portion formed between the stator and the cover, preventing exposure and reducing the risk of deformation, shorting, and contact failure, while also simplifying the filling process and reducing production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If terminal pins are exposed for signal output, then ease of connection is improved, but reliability deteriorates due to deformation, shorting, and contact failure
Solution Approach 1:
A non-conductive material is introduced as an intermediary substance that fills the hollow portion and covers the terminal pins. This mediator protects the terminal pins from external loads and environmental contaminants while still allowing electrical signals to pass through, thus maintaining reliability without completely isolating the terminals.
Solution Approach 2:
The non-conductive material acts as a protective shell or film that encloses the terminal pins. This shell provides mechanical protection against deformation and external loads, while also preventing shorting and contact failure by isolating the pins from water, dust, and dirt.
2Reliability
If terminal pins are covered to prevent exposure, then reliability is improved, but ease of connection deteriorates
Solution Approach 1:
The non-conductive material serves as a mediator that allows electrical connection while providing physical protection. It enables signal transmission through its structure, so connectivity is maintained even though the pins are covered, thus resolving the contradiction between protection and accessibility.
3Reliability
If hollow portion is filled with non-conductive material, then protection against shorting and contaminants is improved, but manufacturing complexity increases
Solution Approach 1:
The non-conductive material is filled into the hollow portion during the insulator manufacturing process itself, before final assembly. This preliminary action integrates the filling step into the existing manufacturing workflow, avoiding the need for separate complex filling operations and reducing overall manufacturing complexity.
Solution Approach 2:
The filling of the non-conductive material is merged with the insulator manufacturing process. By combining these two operations into one integrated process, the patent reduces the number of discrete steps and simplifies the overall manufacturing workflow while still achieving the protective function.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively protects terminal pins from external loads and environmental contaminants, preventing deformation and failure, while optimizing the filling process to decrease production costs and ensure efficient resin application.
Implementation Method 1
The insulator and the cover form a hollow portion therebetween, and the hollow portion is filled with a non-conductive material
Implementation Method 2
While the rotor rotates, a distance between an outer circumferential surface of the rotor and each of the sine phase detection coil and the cosine phase detection coil, is periodically changed. In this case, if electric current is supplied to the exciting coil, induced currents induced by the sine phase detection coil and the cosine phase detection coil are periodically changed according to rotation angle of the rotor.
Implementation Method 3
Variable reluctance resolvers (VR resolvers) used for measurement of a rotating position are known. The VR resolver is formed by arranging a rotor, which is made of a magnetic material, in a stator. The stator has plural magnetic salient poles that are projected from a circular stator core toward a rotation center
Data Source
AI summary
In a variable reluctance resolver having terminal pins at an insulator, a technique for preventing deformation of the terminal pins, shorting between the terminal pins, and contact failure at portions of the terminal pins is provided. A first insulator 300 is formed together with a terminal pin base 311 on which terminal pins 320 are provided. The terminal pins 320 are connected with end portions of windings of a stator coil 500. A cover 330 is mounted on the terminal pin base 311 by covering, and resin is filled inside the cover 330. The resin is also applied to the stator coil 500. The resin filled inside the cover 330 seals the terminal pins 320, and the cover 330 protects the terminal pins 320.